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Abstract
A screening life cycle assessment (LCA) of tomato ketchup has been carried out. The purpose was to identify ‘hot-spots’, that
is parts of the life-cycle that are important to the total environmental impact. The system investigated includes agricultural pro-
duction, industrial refining, packaging, transportation, consumption and waste management. Energy use and emissions were quant-
ified and some of the potential environmental effects assessed. Packaging and food processing were found to be hot-spots for many,
but not all, of the impact categories investigated. For primary energy use, the storage time in a refrigerator (household phase) was
found to be a critical parameter. 1998 Elsevier Science Ltd. All rights reserved.
was to identify key issues associated with the life cycle allocation applied are shown in Table 3. Our ambition
of tomato ketchup, such as (1) the steps of the life cycle was to use site-specific inventory data, whenever poss-
which give rise to the most significant environmental ible. To collect this data and other information, we used
input and output flows, that is hot spots, and (2) major our own questionnaire, interviews and environmental
gaps in the data available. The comprehensive report (in reports. The Swedish producer of ketchup has several
preparation) includes, in addition to the screening LCA: suppliers of tomato paste in Italy, Spain and Portugal;
a comparison of the current packaging system for the inventory data for tomato paste were collected from
ketchup and an alternative one, and an improvement one of the suppliers in Italy. The data for cultivation of
assessment of a selected part of the life cycle. tomatoes were collected from one of the farms supplying
the Italian tomato paste plant. Most of the inventory data
2.2. The product and the system investigated were collected in 1993 and 1994.
The product studied is one of the most common 2.5. The system boundaries
brands of tomato ketchup sold in Sweden; it is marketed
in 1 kg red plastic bottles. The complete system investi- Procedures and results from the inventory analysis
gated is shown in Fig. 1. The packaging systems for tom- have already been presented [5]. Since then, the system
ato paste and ketchup are shown in Figs. 2 and 3, investigated has been expanded to include: production
respectively. The life cycle can be described briefly as of electricity; cultivation of sugar beets; production of
follows. Tomatoes are grown and processed into tomato raw sugar; treatment of the waste water from production
paste in the Mediterranean countries; then the tomato of both the sugar solution and the ketchup; shopping;
paste is transported to Sweden and processed (together and the household phase. Thermal energy was accounted
with other ingredients and water) into ketchup. There- for as the amount used for combustion. Whenever emis-
after, the ketchup is packaged, delivered to retailers and, sion factors were used, emissions from the fuel extrac-
finally, consumed. The tomato paste is packed in aseptic tion (precombustion emissions) were included. For elec-
bags which are placed in steel barrels. Each bag contains tricity from a grid, average country-specific data for
200 l of tomato paste. The plastic bottle used for ketchup electricity production were used when the geographic
is made of polypropylene (PP) and is blow-moulded. It location of the process was known. Otherwise average
consists of five layers: an inner wall of PP; adhesive; a figures for European electricity were used (see Table 3).
barrier layer of ethylenevinylalcohol (EVOH); adhesive; These figures are based on data for the ‘Union for the
and an outer wall of PP. Connection of Production and Transportation of Elec-
The model system was divided into six subsystems. tricity, UCPTE 88’ as presented by BUWAL [6].
For the packaging and household subsystems, alternative To compare the environmental impacts of the two
scenarios were analysed. Table 1 shows a summary of waste management scenarios for the packaging materials
the subsystems, the processes they include and the scen- (see Tables 1 and 2), system expansion with a marginal
arios investigated. For the packaging subsystem, the substitute, oil, was applied [9,13]. Thus, for waste incin-
waste management scenarios investigated are further eration, the energy recovered was subtracted from the
defined in Table 2. scenario’s total energy use. The energy recovered was
also assumed to mean a reduced need of oil for heating
2.3. The functional unit purposes. The emissions from scenarios including waste
incineration were therefore adjusted: the emissions that
The functional unit (FU) is defined as 1000 kg of tom- would have resulted, if oil had been used to generate the
ato ketchup consumed, assuming a 5% loss in the house- amount of energy recovered, were subtracted from the
hold phase. We prepared a questionnaire which was total emissions of the scenario.
answered by 30 persons and collected their ketchup The treatment of waste water, at the municipal plant,
bottles at the point of disposal. This very limited survey was included for the production of ketchup and sugar
indicated: (1) that the household scenarios are realistic solution; the other food processing plants have their own
as to storage time; and (2) that the losses vary signifi- waste water treatment. Since the municipal plant treating
cantly, that is values from 0.5% to 26% were recorded. the effluent from the ketchup production receives 90%
The 5% loss assumed was validated as a reasonable esti- of its load from this particular food industry, site-specific
mate; other losses can easily be simulated with the scen- data from this waste water treatment plant were used.
ario technique. For treatment of the effluent from sugar solution pro-
duction, general data on efficiencies and energy use for
2.4. The inventory analysis and data collection an assumed waste water treatment plant with mechan-
ical, biological and chemical treatment were used [12].
For the inventory analysis, a summary of the pro- This type of plant is the most common in Sweden.
cesses included, the data sources and the principles of Due to data gaps, the following steps were left outside
K. Andersson et al. / Journal of Cleaner Production 6 (1998) 277–288 279
Fig. 1. Principal flow chart of the life cycle of the Swedish tomato ketchup.
the system boundaries: the production of capital goods minium; these materials were omitted, due to the small
(machinery and buildings); the production of citric acid; amounts in which they occur. For the household phase,
the wholesale dealer; transportation from the wholesaler leakage of refrigerants was left outside the system
to the retailer; and the retailer. Likewise, for the ketchup boundaries.
bottles, the production of adhesive, EVOH, pigment, lab- In the cultivation steps, the assimilation of CO2 by
els, glue and ink were omitted due to lack of accessible the crops was not taken into consideration; neither was
data. The aseptic bags used for the tomato paste contain leakage of nutrients and gaseous emissions such as
7% polyethyleneterephthalate (PET) and 0.03% alu- ammonia and nitrous oxide from the fields. Models for
280 K. Andersson et al. / Journal of Cleaner Production 6 (1998) 277–288
Fig. 3. The ketchup packaging system investigated. LDPE is short for low density polyethylene. The dotted lines around EVOH indicate that the
production of EVOH was not included within the system boundaries.
Table 1
The ketchup production subsystems, the processes included and the scenarios investigated
Table 2
The tomato paste and ketchup packaging systems and the different waste management scenarios
Scenario 1 Steel barrels, plastic materials and wood pallets: to landfill Plastic materials: to landfill. Corrugated cardboard: 80% to
recycling and 20% to landfill. Wood pallets: reused 100 times,
then to landfill
Scenario 2a Steel barrels: 70% to recycling and 30% to landfill. PP: 80% to LDPE: to incineration. PP: 80% to incineration and 20% to
incineration and 20% to landfill. LDPE and wood pallets: to landfill. Corrugated cardboard: 80% to recycling and 20% to
incineration incineration. Wood pallets: reused 100 times, then to
incineration
a
Incineration means that the inherent energy is recovered.
Table 3
The processes included, the sources of data and the principles of allocation used for the inventory analysis
a
Tomatoes.
b
Sugar beets.
c: The software ‘LCA Inventory Tool’ (LCAiT).
Thus, the results obtained by mass allocation appear production. Mass allocation yields the requirement of
reasonable. Besides tomato paste, canned peeled 1.7 GJ thermal energy per tonne of product. (The
whole tomatoes and diced tomatoes are produced. requirement of 0.38 GJ electricity was recorded for
Literature data were used to check the stability of the the ketchup production line.) According to literature
results; for canned fruits and vegetables, requirements data, the energy requirements of the product groups
of 5.2 GJ thermal and 0.20 GJ electrical energy per ‘pickles, sauces and salad dressings’ and ‘cooking
tonne have been reported [2]. oils’ are of similar magnitude (ketchup can be
쐌 Co-products in the ketchup plant are salad dressing, regarded as a sauce). For pickles, sauces and salad
cooking oil, jam, mayonnaise and horse-radish; how- dressings, the energy requirement 2.6 GJ thermal plus
ever, the ketchup dominates by mass: 66% of the total 0.48 GJ electrical energy per tonne has been reported;
282 K. Andersson et al. / Journal of Cleaner Production 6 (1998) 277–288
for cooking oils, the corresponding figures are 3.0 GJ 쐌 Eutrophication was found by means of the ‘scenario-
thermal plus 0.24 GJ electrical energy [2]. Since jam based approach’ which divides the category into five
is heated in a process similar to that used for ketchup, subcategories. As a complement to the characteris-
the thermal energy requirement per mass unit should ation results, the inventory parameter BOD
be comparable to the one for ketchup. Mayonnaise (Biological Oxygen Demand) was taken into con-
and horse-radish are produced in relatively small vol- sideration; for some processes BOD is known but not
umes. COD (Chemical Oxygen Demand), and vice versa.
쐌 Photo-oxidant formation was obtained by using the
To enable including the transportation of ketchup
concept of Photochemical Ozone Creation Potentials
between the retailer and the consumer, many assump-
(POCPs) [15,17,18] and inventory results were used
tions had to be made. The basic parameters for calculat-
for substances that lack available weighting factors.
ing the environmental loads caused by shopping are:
쐌 Human toxicity was assessed by using the CML pro-
쐌 the proportion of trips made by car, assumed to be visional and Tellus methods; ecotoxicity was handled
55%; with the CML provisional method [18,19]. In
쐌 the distance driven, assumed to be 2.5 km each addition, for radioactive waste and radon, the inven-
way; and tory results were taken into consideration.
쐌 the amount of groceries bought, assumed to be 10 kg.
The environmental loads were allocated by weight for
the products bought. 3. Results
To include the loss occurring in the household phase,
all of the results from the inventory analysis were multi- The use of primary energy and potential contributions
plied by 1.05. This was done to link the environmental to global warming, ozone depletion, acidification,
loads caused by the losses to their actual geographic eutrophication, photo-oxidant formation, human toxicity
location. For the rest of the system, the calculations were and ecotoxicity, at subsystem level, are presented next.
carried out as if there were no losses. For example, all
of the tomatoes harvested were assumed to be used in 3.1. Energy use
the production of tomato paste. All of the tomato paste
produced was assumed to be used in the production of The use of primary energy and the energy sources are
tomato ketchup, and so on. shown in Fig. 4. The scenario for the household subsys-
For the cultivation steps, we have assumed: that only tem (time for storage in the refrigerator) is critical. The
fertilisers (no manure) are used; and that agricultural figure used for storage in the refrigerator is 4.73 Wh per
land is contaminated with 660 mg zinc, 100 mg arsenic litre and day [4]. Primary energy use in this subsystem
and 60 mg cadmium per kg phosphorous applied as ferti- varies between approximately 10% and 50% of the total.
liser [4]. It is clear that the energy requirements of the food pro-
cessing and the packaging subsystems are also
2.7. The impact assessment important. In food processing, approximately one third
of the energy requirement is for the production of tomato
In the classification and characterisation done we have paste; one third for the other ketchup ingredients; and
followed the Nordic Guidelines [12]. The contributions one third for the ketchup itself. For the packaging subsy-
to the following impact categories were assessed. stem, the scenario is not as critical as for the household
쐌 Global warming was obtained, for direct greenhouse subsystem. Note that the transportation subsystem and
gases, by using Global Warming Potentials (GWPs) the process of shopping have similar energy require-
of the time-horizons 20, 100 and 500 years [14]. ments. The contribution of transportation to the packag-
Indirect greenhouse gases were included to check the ing subsystem is not known, since the form of literature
influence on the results [15,16]. data does not allow one to distinguish efficiently the
쐌 Depletion of stratospheric ozone was worked out by energy used for production from that used for transpor-
using the inventory results for methane, nitrous oxide, tation.
carbon monoxide and non-methane hydrocarbons,
since these substances contribute directly or indirectly 3.2. Global environmental effects
to the effect. No substances for which Ozone
Depletion Potentials (ODPs) are available were ident- The characterisation results for global warming are
ified in the inventory analysis. shown in Fig. 5. The food processing and the packaging
쐌 Acidification was assessed by using the ‘protons subsystems make large contributions to global warming
released approach’ with its minimum and maximum because of their high consumption of fossil fuels. The
scenarios. low contribution from the household subsystem is due
K. Andersson et al. / Journal of Cleaner Production 6 (1998) 277–288 283
to the assumption that only Swedish electricity is used oxidant formation, are shown in Tables 5–9. For acidifi-
and the fact that the Swedish electricity model is domi- cation, the food processing subsystem is an obvious hot-
nated by hydropower and nuclear power; for a 100-year spot (see Table 5). Since the geographic location is of
time frame, the contributions made by the households A significance, it is relevant to analyse the food processing
and B are approximately 2.2 and 26 g CO2-equivalents subsystem further. Depending on the characterisation
per functional unit (FU), respectively. The contributions model chosen, the sulphur dioxide (SO2) emitted in the
made by indirect greenhouse gases are, except for the production of tomato paste is responsible for between
process of shopping, relatively small; they decrease with 70% and 90% of the effect. This life cycle step is here
longer time frames. located specifically in northern Italy; the combination of
For ozone depletion, the inventory results for methane high energy use and the choice of fuel (heavy fuel oil)
(CH4), nitrous oxide (N2O), carbon monoxide (CO) and is the cause of the high SO2-emission. The reason for
non-methane hydrocarbons (NMHC) are shown in the negative contribution shown by the Packaging 2
Table 4. scenario is an avoided emission of SO2, due to the
assumption that the energy recovered from waste incin-
3.3. Regional environmental effects eration replaces heat produced by combustion of oil. The
differences between the results of the minimum and
The contributions assessed for the regional environ- maximum characterisation models vary. The minimum
mental effects, acidification, eutrophication and photo- model excludes the acidifying potential of nitrogen com-
284 K. Andersson et al. / Journal of Cleaner Production 6 (1998) 277–288
Table 4
Inventory results for emissions contributing to ozone depletion in g per FU
Table 6
Characterisation results for eutrophication in kg O2 per FU
Table 8
Characterisation results for photo-oxidant formation in g ethene-equivalents per FU
Agriculture 15 13 12 160
Food processing 32 60 43 190
Packaging 1 6.6 5.9 5.3 340
Packaging 2 8.6 7.7 6.8 330
Transportation 13 12 11 37
Shopping 300 270 240 290
Household A 4.8 ⫻ 10−5 4.3 ⫻ 10−5 3.8 ⫻ 10−5 2.3 ⫻ 10−4
Household B 5.6 ⫻ 10−4 5.0 ⫻ 10−4 4.5 ⫻ 10−4 2.7 ⫻ 10−3
a
Assessed by using the POCPs of Finnveden et al. and Andersson-Sköld et al. [15,17].
b
Assessed by using the POCPs of Heijungs et al. [18].
Table 9 Table 11
Inventory results for substances (without weighting factors) contribu- Contributions to human toxicity assessed according to the Tellus
ting to photo-oxidant formation method
3.4. Toxicity
4. Conclusions and discussion
The characterisation results for human toxicity and
ecotoxicity are presented in Tables 10–12. According to The most important goal of any life cycle study is, of
both the Tellus method for human toxicity and the CML course, to improve and optimise the system. Based on
provisional method for ecotoxicity, the agriculture sub- the study carried out, we have identified parts of the life
system is a hot-spot even though leakage of pesticides cycle that are critical to the total environmental impact
was not quantitatively included. The reason is the con- as well as some major gaps in the available data. The
tent of heavy metals in phosphorous fertilisers. The use of energy has often been employed as an indicator
inventory results for radioactive waste (caused by the of environmental impact. The results presented illustrate
production of electricity) and emissions of radon (caused the complexity in a scientific evaluation of a product’s
by the extraction of coal) are presented in Table 13. environmental performance; the results of the energy
Table 10
Contributions to human toxicity assessed according to the CML provisional method in kg body weight per FU
Table 13
Inventory results for radioactive waste and radon
Agriculture
Food processing 0.78 8.9 8.9 400
Packaging 1 0.71 8.1 8.1 180
Packaging 2 0.71 8.1 8.1 180
Transportation
Shopping
Household A 7.5 ⫻ 10−4 8.5 ⫻ 10−3 8.5 ⫻ 10−3
Household B 8.8 ⫻ 10−3 0.10 0.10
K. Andersson et al. / Journal of Cleaner Production 6 (1998) 277–288 287
data for France, to be 180 MJ per FU including ducts and processes in the food industry. For food sys-
machinery and buildings [4]. Adjusting the calcu- tems, the handling of waste water deserves more
lations made for the cultivation of sugar beets (site- attention. Waste water treatment requires energy and
specific data), results in an extra requirement of 193 chemicals; this produces emissions. It would be relevant
MJ per FU. Altogether, this corresponds to approxi- to simulate alternative scenarios for the waste water
mately 30% of the total estimated energy requirement handling. In the right place, waste water from the food
of the agriculture subsystem. industry would be a source of nutrients or a resource for
쐌 The wholesale and retail step was also left outside the production of biogas.
system boundaries. Literature data for this life cycle The case study reported here is one of the first LCAs
step indicate that the energy requirements for other of a whole food system. In spite of its limitations, it is
products are not at all negligible: 1.43 MJ per kg beer a rather complete study and the collection of site-specific
for storage at the wholesale trader in Switzerland and data contributes to the high quality of data presented.
1.66 MJ per kg bread in the Netherlands [20,21]. Data One of the reasons for the choice of tomato ketchup is
on the total annual energy use of the wholesale and that its life cycle represents a rather common food-pro-
retail step are available for Sweden [22], but there is a duct life cycle: it includes a harvest, a preservation pro-
major data gap that hinders quantification of the share cess (seasonal production), storage, transportation and,
which should be allocated to ketchup. finally, further processing into a consumer product. The
conclusions are of course specific for the tomato ketchup
The practical application of this study is to provide a studied; however, similar results could be expected for
platform for improvement analyses. The calculation jam and juices. Another reason for the choice of ketchup
model constructed (simple spreadsheets in Microsoft was the interest of the Swedish ketchup producer and
Excel) allows for simulations by means of which alterna- their willingness to participate. Without such support, it
tive scenarios for each step can be calculated and evalu- would not have been possible to obtain site-specific data.
ated. The main problem encountered in our endeavour
to apply the LCA methodology to a food system was,
besides the great gaps in accessible data, how to handle Acknowledgements
the agricultural production and the consumer phase; for
both these phases, collection of representative data is The Swedish Waste Research Council is gratefully
only one difficulty. Agricultural production makes spe- acknowledged for funding. We also wish to thank
cial demands on the LCA methodology [4,23–26]. For warmly all who have kindly assisted us with site-specific
instance, it is difficult to determine the system boundary data and patiently answered our many questions. Special
between the technological system and nature; agricul- thanks to Lora Sharp-McQueen who reviewed the
tural production takes place in nature itself and is actu- English of this paper.
ally a part of the environmental system. Ideally, all of
the crops in a crop rotation system should be studied,
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